Methods for forming composite panels

ABSTRACT

A method of forming a composite panel includes providing an initial composite material, heating the initial composite material, molding the initial composite material to form a preliminary composite panel having a main body connected to an outer edge and a laminate layer secured to the outer edge, and folding an exterior edge portion of the outer edge over an interior edge portion to provide an external folded edge having the laminate layer on at least a portion of an outer surface.

FIELD OF EMBODIMENTS OF THE DISCLOSURE

Embodiments of the present disclosure generally relate to compositepanels, and, more particularly, to methods of forming composite panels.

BACKGROUND OF THE DISCLOSURE

Various structures are formed from composite materials. For example,portions of aircraft may be formed from composite materials. Thecomposite material may be or include a polymer matrix reinforced withfibers. Known fibers include glass, carbon, basalt, aramid, or the like.

Internal cabins of aircraft may include numerous composite panels.Composite panels such as sidewall and doorway liners within an internalcabin typically do not include exposed edges. In order to cover edges ofa composite panel, an edge wrapping process is used. Typically, adecorative laminate is wrapped around an edge and glued to a back sideof the panel.

For at least certain composite panels, an edge wrapping process is notamenable to automation. Instead, the edge wrapping process is typicallyperformed manually. The process of manually edge wrapping a laminatearound an edge of a composite panel is time and labor intensive.Moreover, such a manual edge wrapping process may be ergonomicallyawkward.

In one example, a panel is cured in a molding process. After the panelis cured, a decorative laminate is applied in a separate vacuum formingprocess. After the vacuum forming process, excess laminate is wrappedaround the exposed edges, such as by hand. As can be appreciated, such aprocess is time and labor and intensive.

SUMMARY OF THE DISCLOSURE

A need exists for a system and method for efficiently covering aperipheral edge of a composite panel. Further, a need exists for asystem of method for automatically covering a peripheral edge of acomposite panel. Moreover, a need exists for efficiently andcost-effectively forming a composite panel having an edge wrappeddecorative laminate.

With those needs in mind, certain embodiments of the present disclosureprovide a method of forming a composite panel including providing aninitial composite material, heating the initial composite material,molding the initial composite material to form a preliminary compositepanel having a main body connected to an outer edge and a laminate layersecured to the outer edge, and folding an exterior edge portion of theouter edge over an interior edge portion to provide an external foldededge having the laminate layer on at least a portion of an outersurface.

In at least one embodiment, said folding includes folding the exterioredge portion along a groove between the exterior edge portion and theinterior edge portion.

Said providing the initial composite material may include forming theinitial composite material of a thermoplastic matrix and carbon fibers.In at least one embodiment, the carbon fibers are recycled.

In at least one embodiment, said heating includes heating the initialcomposite material to a temperature within a range between 500-650° F.

In at least one embodiment, said molding includes co-molding thepreliminary composite panel along with the laminate layer.

In at least one embodiment, the main body has a first thickness, and theouter edge has a second thickness. The first thickness is greater thanthe second thickness. For example, the first thickness is twice thesecond thickness.

In at least one embodiment, said molding includes forming a groove inthe outer edge. For example, said forming the groove includes formingthe groove between the interior edge portion and the exterior edgeportion. In at least one embodiment, said forming the groove includesforming the groove proximate to the laminate layer.

In at least one embodiment, said folding includes rolling the exterioredge portion of the outer edge onto the interior edge portion. In atleast one embodiment, said folding provides the external folded edgehaving a same thickness as the main body.

The method may also include subsequently compressing the composite panelafter said folding.

Certain embodiments of the present disclosure provide a composite panelincluding a main body connected to an outer edge and a laminate layersecured to the outer edge. An exterior edge portion of the outer edge isfolded over an interior edge portion to provide an external folded edgehaving the laminate layer on at least a portion of an outer surface.

In at least one embodiment, the main body and the outer edge are formedof a thermoplastic matrix and carbon fibers.

In at least one embodiment, the main body has a first thickness, and theouter edge has a second thickness. The first thickness is greater thanthe second thickness. For example, the first thickness is twice thesecond thickness.

In at least one embodiment, the outer edge includes a groove between theinterior edge portion and the exterior edge portion. The groove isproximate to the laminate layer.

In at least one embodiment, the external folded edge has a samethickness as the main body.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a lateral view of an initial composite material,according to an embodiment of the present disclosure.

FIG. 2 illustrates a lateral view of the initial composite materialwithin a heating device, according to an embodiment of the presentdisclosure.

FIG. 3 illustrates a lateral view of a preliminary composite panelwithin a forming tool, according to an embodiment of the presentdisclosure.

FIG. 4 illustrates a lateral view of the preliminary composite panel,according to an embodiment of the present disclosure.

FIG. 5 illustrates a lateral view of the outer edge of the preliminarycomposite panel folded over within the forming tool, according to anembodiment of the present disclosure.

FIG. 6 illustrates a lateral view of a composite panel formed within theforming tool, according to an embodiment of the present disclosure.

FIG. 7 illustrates a flow chart of a method of forming a compositepanel, according to an embodiment of the present disclosure.

FIG. 8 illustrates a perspective front view of an aircraft, according toan embodiment of the present disclosure.

FIG. 9A illustrates a top plan view of an internal cabin of an aircraft,according to an embodiment of the present disclosure.

FIG. 9B illustrates a top plan view of an internal cabin of an aircraft,according to an embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE

The foregoing summary, as well as the following detailed description ofcertain embodiments, will be better understood when read in conjunctionwith the appended drawings. As used herein, an element or step recitedin the singular and preceded by the word “a” or “an” should beunderstood as not necessarily excluding the plural of the elements orsteps. Further, references to “one embodiment” are not intended to beinterpreted as excluding the existence of additional embodiments thatalso incorporate the recited features. Moreover, unless explicitlystated to the contrary, embodiments “comprising” or “having” an elementor a plurality of elements having a particular property may includeadditional elements not having that property.

Certain embodiments of the present disclosure provide a composite panelincluding a thermoplastic layer having a matrix material (such as formedof thermoplastic fibers) and fiber material (such as carbon fibers). Atleast one decorative laminate is disposed on at least one face of thethermoplastic layer. An edge portion of the thermoplastic layer has areduced thickness. The reduced thickness edge portion has a firstsegment separated from a second segment by a groove. The first segmentand second segment, when combined together, have a same thickness as anadjoining main body portion.

Certain embodiments of the present disclosure provide a method ofmanufacturing a composite panel, including performing a first-stagecompression molding to form a preliminary panel. The preliminary panelincludes an interior edge portion and an exterior edge portion coupledtogether by a groove. The method further includes folding the exterioredge portion over the interior edge portion along the groove.

Embodiments of the present disclosure provide high quality, structurallysound composite panels that meet Federal Aviation Administration (FAA)requirements with respect to flammability. Further, embodiments of thepresent disclosure provide low cost and efficient manufacturing methodsfor forming composite panels. Embodiments of the present disclosureprovide composite panels having edge-wrapped decorative laminates thatare formed in less time and at less cost than known manual edge-wrappingtechniques.

FIG. 1 illustrates a lateral view of an initial composite material 100,according to an embodiment of the present disclosure. The initialcomposite material 100 includes a top surface 102 coupled to a bottomsurface 104 through peripheral edges 106. The initial composite material100 is formed of a thermoplastic matrix 108 and carbon fibers 110. Thethermoplastic matrix 108 includes a plurality of thermoplastic fibers112. The carbon fibers 110 and the thermoplastic fibers 112 aredistributed throughout the initial composite material 100. The carbonfibers 110 and the thermoplastic fibers 112 can be randomly distributedthroughout the initial composite material 100. In at least oneembodiment, the carbon fibers 110 may be recycled carbon fibers, such asprovided from scrap from portions of a manufactured aircraft.

FIG. 2 illustrates a lateral view of the initial composite material 100within a heating device 120, according to an embodiment of the presentdisclosure. The heating device 120 can be an oven, autoclave, or thelike. As another example, the initial composite material 100 can beheated by an external heating device, such as a blowtorch, for example.

Referring to FIGS. 1 and 2, in order to form a composite panel accordingto an embodiment of the present disclosure, the initial compositematerial 100 is first pre-heated so that the thermoplastic fibers 112melt. The initial composite material 100 is heated within (and/or by)the heating device 120. For example, the initial composite material 100is heated to a temperature within a range of 500-650° F. The range canbe within the range 525-625° F. When the initial composite material 100is heated to an initial pre-heated temperature (such as within a rangeof 500-650° F.), the thermoplastic matrix 108 including thethermoplastic fibers 112 melts.

FIG. 3 illustrates a lateral view of a preliminary composite panel 130within a forming tool 140, according to an embodiment of the presentdisclosure. The forming tool 140 is an example of a forming system. Theforming tool 140 can be a forming press, die, mold, or the like.Referring to FIGS. 1-3, after the initial composite material 100 ispreheated, the initial composite material 100 is placed onto an over abase 142 of the forming tool 140. A laminate layer 132 is positionedover a portion of the base 142, underneath an edge 134 of thepreliminary composite panel 130. The laminate layer 132 is configured toform an edge-wrapped decorative, as described herein. In at least oneembodiment, the laminate layer 132 is a separate and distinct piece. Thelaminate layer 132 can be formed of the same material as the initialcomposite material 100, the thermoplastic matrix 108, the carbon fibers110, another thermoplastic or polymer, and/or the like.

Accordingly, the laminate layer 132 is co-molded along with thepreliminary composite panel 130, instead of being separately manuallyaffixed in a subsequent process. As such, the process of forming acomposite panel according to embodiments of the present disclosure isless costly and less labor intensive.

The forming tool 140 may be coupled to a heater 144, which heats thebase 142 and/or an upper press 146. Optionally, the forming tool 140 maynot be coupled to a heater. As another example, the forming tool 140 maybe within and/or otherwise coupled to the heating device 120.

After the laminate layer 132 is disposed on the base 142, and theinitial composite material 100 is disposed on the base 142 having anexterior edge portion over the laminate layer 132, the upper press 146is urged onto the initial composite material 100 in the direction ofarrow A, thereby forming the preliminary composite panel 130. The upperpress 146 includes an interior body-forming segment 148 connected to anedge-forming segment 150. The interior body-forming segment 148 has afirst depth 152, and the edge-forming segment 150 has a second depth 154that is greater than the first depth 152. For example, the second depth154 may be twice the first depth 152. The edge-forming segment 150 alsoincludes a groove-forming protuberance 156 extending downwardlytherefrom. The groove-forming protuberance 156 can be across a centralportion of the edge-forming segment 150.

As the upper press 146 compresses the initial composite material 100against the base 142, the heated initial composite material 100compresses in response thereto. As the initial composite material 100 iscompressed, the melted thermoplastic matrix 108 bonds the carbon fibers110, thereby forming a homogenous structure, thereby resulting in thepreliminary composite panel 130.

FIG. 4 illustrates a lateral view of the preliminary composite panel130, according to an embodiment of the present disclosure. Referring toFIGS. 1-4, the preliminary composite panel 130 is formed by the upperpress 146 urging into and compressing the initial composite material 100into the base 142 in the direction of arrow A. The preliminary compositepanel 130 includes a main body 160, formed by the interior body-formingportion 148 compressing into the initial composite material 100 in thedirection of arrow A, and an outer edge 162, formed by the edge-formingsegment 150 compressing into the initial composite material 100 in thedirection of arrow A. The main body 160 has a first thickness 164, andthe outer edge 162 has a second thickness 166. The first thickness 164is greater than the second thickness 166. In at least one embodiment,the first thickness 164 is twice the second thickness 166.

A groove 168 is formed in the outer edge 162. The groove 168 is formedbetween an interior edge portion 170 and an exterior edge portion 172.The interior edge portion 170 and the exterior edge portion 172 may bethe same length. Optionally, the interior edge portion 170 and theexterior edge portion 172 may have different lengths. As shown, thegroove 168 may be formed to provide a first half, such as the interioredge portion 170, and a second half, such as exterior edge portion 172.

The groove 168 is formed proximate to the laminate layer 132. Forexample, as shown, the groove 168 is over the laminate layer 132. Inthis manner, the laminate layer 132 is positioned around at least aportion of the groove 168 when the outer edge 162 is folded, asdescribed herein.

The laminate layer 132 can be a thin layer of material having athickness than is less than the second thickness 166. The laminate layer132 is bonded to and extends over a face, such as a lower surface 176 ofthe outer edge 162. In at least one embodiment, the laminate layer 132extends over the lower surface 176 along an entire length of the outeredge 162. Optionally, the laminate layer 132 may extend over less thanan entire length of the outer edge 162. As another example, the laminatelayer 132 may extend over a lower surface of at least a portion of themain body 160 in addition to at least a portion of the outer edge 162.

As shown, the groove 168 can be a rectangular notch formed into an uppersurface 178 of the outer edge 162. The groove 168 may extend over anentire width of the preliminary composite panel 130. Optionally, thegroove may extend over less than entire width of the preliminarycomposite panel 130. The shape of the groove 168 is determined by theshape of the groove-forming protuberance 156 of the forming tool 140.Optionally, the groove 168 (and the groove-forming protuberance 156) maybe shaped differently, such as triangular, semi-circular, or the like.

The groove 168 may be any shape such that when the preliminary compositepanel 130 is folded over within the forming tool 140, as describedherein, the folded portion fits well. For example, fitting well meansleaving a slight gap to allow space for adhesive, a slight interferenceto compress to provide a solid panel, a close tolerance fit, and/or thelike. As another example, a panel having a complex curved shape mayinclude a groove 168 having a complex curvature to allow for a properfit. Further, the groove 168 need not be formed by the shape of a toolor cutter. For example, a cutter may make multiple passes at differentorientations to carve out a groove shape that is not the shape of thetool.

As noted, the forming tool 140 forms the preliminary composite panel 130by compressing the initial composite material 100, thereby bonding thethermoplastic matrix 108 to the carbon fibers 110, and bonding thelaminate layer 132 to the lower surface 176 below the groove 168.

FIG. 5 illustrates a lateral view of the outer edge 162 of thepreliminary composite panel 130 folded over within the forming tool 140,according to an embodiment of the present disclosure. Referring to FIGS.1-5, after the upper press 146 forms the preliminary composite panel130, as shown in FIGS. 3 and 4, the upper press 146 is moved off thepreliminary composite panel 130 in the direction of arrow B. The upperpress 146 can be operatively coupled to an actuator 180, such as amotor, which automatically pivots, lifts, opens, or otherwise removesthe upper press 146 in relation to the preliminary composite panel 130.

In at least one embodiment, the forming tool also includes a roller 182.The roller 182 can be part of, or operatively coupled to, the base 142.The roller 182 can be positioned proximate to the groove 168, shown inFIG. 4. The roller 182 can be operatively coupled to an actuator 184,which is configured to operate the roller 182.

After the upper press 146 is moved off the preliminary composite panel130, the roller 182 is operated to roll, fold, or otherwise move theexterior edge portion 172 over the interior edge portion 170 about (forexample, along) the groove 168. For example, the roller 182 rolls theexterior edge portion 172 onto the interior edge portion 170. Becausethe exterior edge portion 172 and the interior edge portion 170 can behalf the thickness of the main body 160, the ensuring folded outer edge162 can be the same thickness as the main body 160. Further, the outeredge 162 (after folding) includes the laminate layer 132 folded aroundan outer surface 189 of an external folded edge 190 (formed by theexterior edge portion 172 folded over the interior edge portion 170),thereby providing an automatically formed edge wrapped edge portion. Assuch, a composite panel 200 is formed.

FIG. 6 illustrates a lateral view of the composite panel 200 formedwithin the forming tool 140, according to an embodiment of the presentdisclosure. After the external folded edge 190 is formed, as describedwith respect to FIG. 5, the upper press 146 can once again urged ontothe composite panel 200, thereby compressing the external folded edge190, which bonds the exterior edge portion 172 to the interior edgeportion 170 and the laminate layer 132 around the external folded edge190. Thus, after the external folded edge is formed, the composite panel200, including the laminate layer 132, can be subsequently compressed.Alternatively, the upper press 146 may not be urged onto the compositepanel 200 after the external folded edge 190 is formed (as shown in FIG.5).

FIG. 7 illustrates a flow chart of a method of forming the compositepanel, according to an embodiment of the present disclosure. Referringto FIGS. 1-7, the method begins at 300, at which the initial compositematerial 100 is provided. At 302, the initial composite material 100 isheated, such as within the heating device 120, such as to a temperaturewithin a range of 500-650° F. Next, at 304, the initial compositematerial 100 is molded, such as by the forming tool 140, to form thepreliminary composite panel 130 having the main body 160 connected to anouter edge 162 and a laminate layer 132 secured to the outer edge 162.The initial composite material 100 remains heated (such as within arange of 400-500° F.) during the molding. The molding can occur throughcompression, such as within the forming tool 140, for a period of 2minutes or less, for example. At 306, the exterior edge portion 172 ofthe outer edge 162 is folded over the interior edge portion 170 toprovide the external folded edge 190 having the laminate layer 132 onthe outer surface 189, thereby providing the composite panel 200.

The composite panel 200 may provide interior walls within an internalcabin of a vehicle, such as a commercial aircraft.

FIG. 8 illustrates a perspective top view of a vehicle, such as anaircraft 10, according to an embodiment of the present disclosure. Theaircraft 10 includes a propulsion system 12 that includes two engines14, for example. Optionally, the propulsion system 12 may include moreengines 14 than shown. The engines 14 are carried by wings 16 of theaircraft 10. In other embodiments, the engines 14 may be carried by afuselage 18 and/or an empennage 20. The empennage 20 may also supporthorizontal stabilizers 22 and a vertical stabilizer 24.

The fuselage 18 of the aircraft 10 defines an internal cabin, which maybe defined by interior sidewall panels that connect to a ceiling and afloor. The internal cabin may include a cockpit, one or more worksections (for example, galleys, personnel carry-on baggage areas, andthe like), one or more passenger sections (for example, first class,business class, and economy sections), and an aft section. Overheadstowage bin assemblies may be positioned throughout the internal cabin.Various portions of the internal cabin, including sidewall panels, theceiling, the floor, the stowage bin assemblies, and the like may beformed by composite panels, such as shown and described herein.

Alternatively, instead of an aircraft, embodiments of the presentdisclosure may be used with various other vehicles, such as automobiles,buses, locomotives and train cars, seacraft, spacecraft, and the like.

FIG. 9A illustrates a top plan view of an internal cabin 30 of anaircraft, according to an embodiment of the present disclosure. Theinternal cabin 30 may be within a fuselage 32 of the aircraft. Forexample, one or more fuselage walls may define an interior of theinternal cabin 30. The interior of the internal cabin 30 is defined bysidewall panels that connect to a ceiling and a floor. The sidewallpanels include lateral segments that connect to ceiling segments. Thelateral segments define lateral wall portions, while the ceilingsegments define at least portions of the ceiling within the internalcabin 30.

The internal cabin 30 includes multiple sections, including a frontsection 33, a first class section 34, a business class section 36, afront galley station 38, an expanded economy or coach section 40, astandard economy or coach section 42, and an aft section 44, which mayinclude multiple lavatories and galley stations. It is to be understoodthat the internal cabin 30 may include more or less sections than shown.For example, the internal cabin 30 may not include a first classsection, and may include more or less galley stations than shown. Eachof the sections may be separated by a cabin transition area 46.

As shown in FIG. 9A, the internal cabin 30 includes two aisles 50 and 52that lead to the aft section 44. Optionally, the internal cabin 30 mayhave less or more aisles than shown. For example, the internal cabin 30may include a single aisle that extends through the center of theinternal cabin 30 that leads to the aft section 44.

Seat assemblies 90 are positioned throughout the internal cabin 30. Theseat assemblies 00 may be arranged in rows 91.

FIG. 9B illustrates a top plan view of an internal cabin 80 of anaircraft, according to an embodiment of the present disclosure. Theinternal cabin 80 may be within a fuselage 81 of the aircraft. Forexample, one or more fuselage walls may define the interior of theinternal cabin 80. The internal cabin 80 includes multiple sections,including a main cabin 82 having passenger seat assemblies 90, and anaft section 85 behind the main cabin 82. It is to be understood that theinternal cabin 80 may include more or less sections than shown.

The internal cabin 80 may include a single aisle 84 that leads to theaft section 85. The single aisle 84 may extend through the center of theinternal cabin 80 that leads to the aft section 85. For example, thesingle aisle 84 may be coaxially aligned with a central longitudinalplane of the internal cabin 80.

In at least one embodiment, portions of the internal cabins 30 (shown inFIG. 9A) and 30 (shown in FIG. 9B) of the aircraft are formed bycomposite panels, as described with respect to FIGS. 1-7.

As described herein, embodiments of the present disclosure providefaster, cheaper, and more efficient methods of a forming compositepanel. Embodiments of the present disclosure provide systems and methodsfor efficiently covering a peripheral edge of a composite panel.Further, embodiments of the present disclosure provide systems ofmethods for automatically covering a peripheral edge of a compositepanel, such as via a forming system.

Embodiments of the present disclosure provide systems and methods forefficiently forming edge-wrapped composite panels. Unlike conventional,manual edge wrapping methods, embodiments of the present disclosureprovide systems and methods that can efficiently and automaticallyprovide edge wrapped decorative laminates around edges of compositepanels. The decorative laminate is not trimmed, as in prior knownmethods, thereby providing an efficient forming method that producesless waste.

While various spatial and directional terms, such as top, bottom, lower,mid, lateral, horizontal, vertical, front and the like may be used todescribe embodiments of the present disclosure, it is understood thatsuch terms are merely used with respect to the orientations shown in thedrawings. The orientations may be inverted, rotated, or otherwisechanged, such that an upper portion is a lower portion, and vice versa,horizontal becomes vertical, and the like.

As used herein, a structure, limitation, or element that is “configuredto” perform a task or operation is particularly structurally formed,constructed, or adapted in a manner corresponding to the task oroperation. For purposes of clarity and the avoidance of doubt, an objectthat is merely capable of being modified to perform the task oroperation is not “configured to” perform the task or operation as usedherein.

It is to be understood that the above description is intended to beillustrative, and not restrictive. For example, the above-describedembodiments (and/or aspects thereof) may be used in combination witheach other. In addition, many modifications may be made to adapt aparticular situation or material to the teachings of the variousembodiments of the disclosure without departing from their scope. Whilethe dimensions and types of materials described herein are intended todefine the parameters of the various embodiments of the disclosure, theembodiments are by no means limiting and are exemplary embodiments. Manyother embodiments will be apparent to those of skill in the art uponreviewing the above description. The scope of the various embodiments ofthe disclosure should, therefore, be determined with reference to theappended claims, along with the full scope of equivalents to which suchclaims are entitled. In the appended claims, the terms “including” and“in which” are used as the plain-English equivalents of the respectiveterms “comprising” and “wherein.” Moreover, the terms “first,” “second,”and “third,” etc. are used merely as labels, and are not intended toimpose numerical requirements on their objects. Further, the limitationsof the following claims are not written in means-plus-function formatand are not intended to be interpreted based on 35 U.S.C. § 112(f),unless and until such claim limitations expressly use the phrase “meansfor” followed by a statement of function void of further structure.

This written description uses examples to disclose the variousembodiments of the disclosure, including the best mode, and also toenable any person skilled in the art to practice the various embodimentsof the disclosure, including making and using any devices or systems andperforming any incorporated methods. The patentable scope of the variousembodiments of the disclosure is defined by the claims, and may includeother examples that occur to those skilled in the art. Such otherexamples are intended to be within the scope of the claims if theexamples have structural elements that do not differ from the literallanguage of the claims, or if the examples include equivalent structuralelements with insubstantial differences from the literal language of theclaims.

What is claimed is:
 1. A method of forming a composite panel,comprising: providing an initial composite material; heating the initialcomposite material; molding the initial composite material to form apreliminary composite panel having a main body connected to an outeredge and a laminate layer secured to the outer edge; and folding anexterior edge portion of the outer edge over an interior edge portion toprovide an external folded edge having the laminate layer on at least aportion of an outer surface.
 2. The method of claim 1, wherein saidfolding comprises folding the exterior edge portion along a groovebetween the exterior edge portion and the interior edge portion.
 3. Themethod of claim 1, wherein said providing comprises forming the initialcomposite material of a thermoplastic matrix and carbon fibers.
 4. Themethod of claim 3, wherein the carbon fibers are recycled.
 5. The methodof claim 1, wherein said heating comprises heating the initial compositematerial to a temperature within a range between 500-650° F.
 6. Themethod of claim 1, wherein the said molding comprises co-molding thepreliminary composite panel along with the laminate layer.
 7. The methodof claim 1, wherein the main body has a first thickness, and the outeredge has a second thickness, and wherein the first thickness is greaterthan the second thickness.
 8. The method of claim 7, wherein the firstthickness is twice the second thickness.
 9. The method of claim 1,wherein said molding further comprises forming a groove in the outeredge.
 10. The method of claim 9, wherein said forming the groovecomprises forming the groove between the interior edge portion and theexterior edge portion.
 11. The method of claim 10, wherein said formingthe groove further comprises forming the groove proximate to thelaminate layer.
 12. The method of claim 1, wherein said foldingcomprises rolling the exterior edge portion of the outer edge onto theinterior edge portion.
 13. The method of claim 1, wherein said foldingprovides the external folded edge having a same thickness as the mainbody.
 14. The method of claim 1, further comprising subsequentlycompressing the composite panel after said folding.
 15. A compositepanel, comprising: a main body connected to an outer edge; and alaminate layer secured to the outer edge, wherein an exterior edgeportion of the outer edge is folded over an interior edge portion toprovide an external folded edge having the laminate layer on at least aportion of an outer surface.
 16. The composite panel of claim 15,wherein the main body and the outer edge are formed of a thermoplasticmatrix and carbon fibers.
 17. The composite panel of claim 15, whereinthe main body has a first thickness, and the outer edge has a secondthickness, and wherein the first thickness is greater than the secondthickness.
 18. The composite panel of claim 17, wherein the firstthickness is twice the second thickness.
 19. The composite panel ofclaim 15, wherein the outer edge comprises a groove between the interioredge portion and the exterior edge portion, wherein the groove isproximate to the laminate layer.
 20. The composite panel of claim 15,wherein the external folded edge has a same thickness as the main body.